Sports boot construction

ABSTRACT

A sports boot and a method for constructing the sports boot are disclosed comprising a unitary body and an external upper assembly. In the current embodiment, the unitary body has a sole portion, an upper portion, and an ankle cuff portion, and comprises injection-molded ethylene vinyl acetate. The external upper assembly is of composite construction from relatively rugged materials, and, in a current embodiment, includes side panels, forefoot panels, and one or more instep panels. The external upper assembly is attached to the unitary body to form the boot.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of Provisional Application No.61/177,934, filed May 13, 2009, the entire disclosure of which is herebyincorporated by reference herein.

BACKGROUND

The construction of boots, and in particular sports boots, has beenevolving over time. Sports boots often present a large number ofcompeting objectives that a designer must consider. For example, oftenlow weight and ruggedness are both high priorities. Because sports bootsare typically worn and actively in use for long periods of time, theymust be comfortable. However, in many applications such as snow sports,the sports boots must also be responsive to the user such that attachedsports equipment, for example skis, snowboards, and the like, can bereadily and precisely controlled. Also, because sports boots aretypically subjected to relatively rigorous usage and difficultenvironments, it is important that they be constructed ruggedly and forendurance.

Prior art sports boots typically respond to the various objectives byengineering greater complexity into the sports boots, which can greatlyincrease costs and provide increasing modes for boot failure. Inparticular, increasing parts count in the design of sports boots canresult in high material costs and high assembly costs. There is a needfor a sports boot that provides lightweight, rugged construction,comfort, responsiveness, and ease of construction.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This summary is not intended to identify key features ofthe claimed subject matter, nor is it intended to be used as an aid indetermining the scope of the claimed subject matter.

A sports boot and method for fabricating the sports boot are disclosed.The sports boot includes a unitary body having a sole portion and anupper portion. The upper portion includes a toe portion configured toenclose a portion of a user's foot, and a cuff portion configured towrap about a user's ankle. A relatively rigid or semi-rigid elongatesupport is attached to the cuff portion of the unitary body. An externalupper assembly is attached to the unitary body and covers a portion ofthe unitary body. A closure means such as a lacing structure is alsoprovided.

In an embodiment of the invention, the unitary body comprisesinjection-molded ethylene vinyl acetate.

In an embodiment of the invention, the external upper assembly comprisesa side panel, a forefoot panel, and an instep panel that arepreassembled prior to attachment to the unitary body.

In an embodiment of the invention, an inner surface of the cuff portiondefines a recess that is shaped to receive the elongate support, suchthat the elongate support is flush with the inner surface of the cuffportion.

In an embodiment of the invention, reinforcing panels are attached tothe unitary body to support attachment of the external upper assembly tothe unitary body.

In an embodiment of the invention, the unitary body includes a pluralityof thickened sections that are not covered by the external upperassembly.

A method of constructing the sports boot is disclosed that includesinjection molding the unitary body, attaching a substantially rigidsupport to the back portion of the unitary body, affixing a plurality ofreinforcing panels to an outer surface of the unitary body, forming anexternal upper assembly, and fixedly attaching the external upperassembly to the unitary body.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated as the same become betterunderstood by reference to the following detailed description, whentaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a side view of an assembled boot in accordance with thepresent invention;

FIG. 2 is a side view of a unitary body portion of the boot shown inFIG. 1, showing a back support attached the rear portion of the unitarybody;

FIG. 3 shows a side view of the unitary body and back support shown inFIG. 2, with support panels and lace guide webbing attached to an outersurface of the unitary body;

FIG. 4 is a partially exploded side view of the boot shown in FIG. 1,showing an external upper assembly and the unitary body;

FIG. 5 is a partially exploded side view of the boot shown in FIG. 1showing installation of an optional external arch support structure to abottom of the unitary body.

DETAILED DESCRIPTION

Footwear, for example sports boots, and a method for constructing suchfootwear are disclosed that provide advantages of lightweight, highquality, simplified construction and lower cost. FIG. 1 shows a sideview of a sports boot 100 constructed in accordance with the presentinvention. In this embodiment, the sports boot 100 may be suitable forsnow sports such as snowboarding and the like.

The sports boot 100 is constructed with a unitary body 110 thatsubstantially surrounds a user's foot. As disclosed below, in thecurrent embodiment the unitary body 110 includes a sole portion 112, anupper portion 114 (FIG. 2), and a cuff portion 118 (FIG. 2), wherein thesole portion 112, upper portion 114, and cuff portion 118 are all formedtogether as a unit, in a single body. For example, in a currentembodiment the unitary body 110 is formed by injection molding. Anexternal upper assembly 150, which is typically of a compositeconstruction, is then fixedly attached to the unitary body 110 to definethe boot 100. A structural support 126 is attached to provide thedesired and targeted rigidity to the boot 100. In various embodiments ofthe invention, additional elements may be included, for example, tofacilitate attachment of the upper assembly 150 to the unitary body 110.

An exemplary unitary body 110, which provides the foundation for theboot 100, will now be described with reference to FIG. 2, which shows aside view of the unitary body 110 in isolation. The unitary body 110comprises a single structure that may be formed using any suitableconventional method for making unitary components having the complexshape as described herein. In an exemplary embodiment, the unitary body110 is formed from injection-molded ethylene vinyl acetate (“IMEVA”).

The unitary body 110 comprises a sole portion 112 defining anundersurface of the body 110 with an upper portion 114 extendingupwardly from the perimeter of the sole portion 112. The upper portion114 includes a toe portion 116 that surrounds at least part of theuser's toes. A cuff portion 118 extends upwardly about a user's ankle.In this embodiment, the sole portion 112 includes thicker tread portions113 that are adapted to engage the ground. However, it is contemplatedthat a separate tread or outer sole (not shown) may alternatively beaffixed or otherwise attached to the sole portion 112 to provide aground-engaging surface. A separate tread could be used, for example toprovide a surface having enhanced wear characteristics, in order toprotect or reduce wear and tear on the unitary body 110.

In the unitary body 110 shown in FIG. 2, thicker rear elements 120, 121and a toe element 122 are provided. The thickened rear and toe elements120, 121, 122 are preferably an integrally formed portion of the unitarybody 110, and may provide a number of functions, including to provideadditional strength or wear resistance in key areas, to tailor theflexibility or other mechanical attributes of the unitary body 110, tobetter engage external apparatus such as bindings and/or straps, todefine attachment regions for other components, to provide additionalcomfort and/or performance characteristics to the user (for example,providing J-bar supports at the ankle), to improve the aestheticappearance of the sports boot 110, and the like. For example, in theFIGURES the thicker rear elements 120, 121 are provided with transverseridges that provide a desired flexibility for dorsiflexion of the user'sfoot. Of course, relatively thinner portions of the unitary body 110 maysimilarly be provided.

The front of the unitary body 110 defines an elongate open portion orslot 124, to cooperate with the external upper assembly 150 (FIG. 1) tofacilitate receiving the user's foot.

In the current embodiment, a relatively rigid (semi-rigid) elongatesupport 126 is attached to the back portion of the unitary body 110. Itwill be appreciated that nothing is perfectly rigid. Semi-rigid andrelatively rigid are used herein interchangeably and are expresslydefined to mean significantly more rigid than the unitary body, andtherefore in the assembly, operable to providing rigidity to the unitarybody 110. The relatively rigid elongate support 126 provides a desiredlevel of rigidity to unitary body 110, which may be selectively definedby the design parameters of the support 126, for example, the materialselection, thickness, and shape, as will be appreciated by persons ofskill in the art. The elongate support 126 is attached to the unitarybody 110 in any convenient means, for example, by affixing the supportwith a suitable adhesive, constructing the unitary body 110 with arecess sized to receive the support 126, forming an internal pocket inthe unitary body 110 for slidably receiving the support 126, or thelike. The elongate support 126 may optionally include a lower portionthat defines a heel counter 128 that is sized and shaped to extendgenerally about a heel of the user.

Although not shown in the FIGURES, a relatively rigid toe cap, which maybe formed from the same material as the elongate support 126, may beinserted and affixed to the toe portion of the unitary body 110. Theunitary body 110 would preferably be provided with a recess forreceiving the rigid toe cap, such that the toe cap is flush with aninner surface of the unitary body 110. Optionally, a gusset 125 may beattached to an inner surface of the unitary body 110, near the toe endof the open portion 124, to deter moisture from entering the sports boot100.

FIG. 3 shows a side view of the unitary body 110 and elongate support126, wherein additional pieces have been attached to the unitary body110. At this stage of assembly, a cuff reinforcing panel 130 is securelyattached to the cuff portion 118 of the unitary body 110. In thisembodiment, the cuff reinforcing panel 130 is generally U-shaped andattached to the unitary body 110 by stitching and bonding. A secondsimilar cuff reinforcing panel (not visible) is attached on the oppositeside of the unitary body 110. The cuff reinforcing panels 130 arerelatively strong panels formed from any suitable material orcombination of materials, which may include natural fibers and/orpolymeric materials, for example. In one embodiment, the cuffreinforcing panels 130 comprise super-tough nylon panels. The cuffreinforcing panels 130 provide attachment elements or anchors forsupporting hooks 131 for a lace 140 (FIG. 4). Of course, if a differentfastening mechanism were desired, for example, straps with hooks andloops type materials or the like, the cuff reinforcing panels 130 mayprovide anchors for such alternative fastening elements. Although thehooks 131 are shown attached with stitching, alternative or additionalattachment means may be used, including, for example, rivets, adhesives,or the like.

In the present embodiment, additional reinforcing panels 132 aresimilarly attached to the upper portion 114. The additional reinforcingpanels 132 provide additional attachment structure, for example tosupport fastening elements. In the present exemplary embodiment, theadditional reinforcing panels 132 provide an anchoring for webbing 134to provide keepers for retaining a lace (not shown). The webbing 134 isattached to the additional reinforcing panels 132 with stitching, whichmay extend through the unitary body 110. Backing or other panels (notshown) may similarly be provided on an inner surface of the unitary body110, for example opposite the reinforcing panels 130, 132, to providestitching support.

Although not required for the present invention, apertures 136 areformed through the unitary body 110 near the open portion 124, and thewebbing 134 extends through the apertures 136. It will be appreciatedthat any number of reinforcing panels may be used, depending on theparticular application, and the reinforcing panels may be attached to aninterior or an exterior surface of the unitary body 110. It iscontemplated that the unitary body 110 may be provided with recessesthat are sized and configured to receive the reinforcing panels 130,132. Such recesses may be readily incorporated into a mold for theunitary body 110, for example, and would enable more precise andrepeatable positioning the reinforcing panels.

FIG. 4 shows a partially exploded view of the sports boot 100 with theexternal upper assembly 150 (shown for reference with the unitary bodylace hooks 131 in phantom and the lace 140 in place). The external upperassembly 150 is fabricated of composite construction primarily fromrelatively rugged and aesthetically pleasing materials, typically sewnor otherwise assembled to define a closure apparatus for the sports boot100. In this embodiment, the external upper assembly 150 includes: (i)side panels 152 that attach to and overlie a portion of the unitary body110, (ii) forefoot panels 154 attached to the unitary body 110 over thewebbing 134, (iii) one or more instep panels 156 that attach to andextend over the toe portion 116 of the unitary body 110, and (iv) atongue 158.

The external upper assembly 150 is fixedly attached to the unitary body110, for example by stitching 127 and/or bonding. It will be appreciatedthat a portion of the stitching attaching the external upper assembly150 preferably is disposed to engage the reinforcing panels 130, 132. Inaddition, the stitching will preferably also engage the webbing 134. Theexternal upper assembly 150 may be formed from any number of suitablematerials, including natural and man-made materials, as are known in theart.

FIG. 5 shows an optional arch support 160 that may be attached to abottom surface of the unitary body 110.

In a particular embodiment of the present method for constructingfootwear that is particularly suited to fabricating highback snowboardboots and the like, the fabrication steps include:

-   -   1. Forming the unitary body 110, for example, from        injection-molded EVA (IMEVA);    -   2. Attaching the elongate support 126 to the unitary body 110,        the support 126 optionally including the heel counter 128;    -   3. Bonding and/or stitching strategically located reinforcing        panels 130, 132 to the unitary body 110;    -   4. Attaching the webbing 134 for lace keepers to the unitary        body 110 with attachment to or through the support panels 132;    -   5. Attaching the lace hooks 131 to the unitary body 110 with        attachment to or through support panels 130;    -   6. Fabricating the external upper assembly 150;    -   7. Fixedly attaching the external upper assembly 150 to the        unitary body 110; and    -   8. Optionally, attaching the arch support 160 to the sole        portion 112 of the unitary body 110.

Variations on this method will be apparent to persons of skill in theart, without departing from the present invention, and the order of thesteps recited above is generally not important, excepting steps havingobvious precedence.

It will be appreciated that the disclosed boot and method provide manysignificant advantages over prior art constructions. For example, theunitary body 110 eliminates the need for many additional parts that arefound in conventional sports boot construction, thereby reducing costsof fabrication and assembly, and providing a very lightweight boot. Inparticular, the method may be practiced without lasting the unitary body110. If the unitary body 110 is formed from IMEVA, for example, the bodymay be formed to closely conform to a desired liner (not shown),providing a better fit between the boot and liner that cannot beachieved with conventional lasting due to the need to remove the last.

Moreover, the IMEVA unitary body may be formed with side wall surfaceshaving J-bar shaping to enhance the J-bars on a liner. (An exemplaryJ-bar is described in U.S. Pat. No. 7,140,128, to Huckle). The IMEVAstructural material may be selected and the shape tuned to achieve adesired flex and support functionality. Design choices for the unitarybody 110, for example, the thicker rear and toe elements 120, 121, 122,can provide wear surfaces without the need for additional parts orconstruction steps.

It will be appreciated from the FIGURES that in the current embodimentthe unitary body 110 is constructed with thicker portions 120, 121, 122at locations that are not covered by the external upper assembly 150.The additional thickness therefore provides greater wear resistance atlocations that are not protected by the upper assembly 150, and alsoprovides aesthetic benefits.

Although a lacing-type fastening mechanism is shown, it will be readilyapparent that other fasting mechanisms may be used, for example cable,BOA®, Velcro®, and the like.

It is contemplated that in some embodiments it may be desirable to addadditional structural, aesthetic, or wear members. For example, a solemember may be affixed to a bottom of the unitary body, or other wearpanels may be provided to outer surfaces such as the toe or heel of theunitary body. A removable, internal insole may be provided. It iscontemplated that the sports boot 100 may be used with a removableliner, as is known in the art. In particular, the removable liner outersurface may be formed to conform closely with the inner surface of theunitary body 110, perhaps including engagement members such as channelsand ridges, to lock the position of the removable liner in the boot. Itis also contemplated that an internal sock or liner may be affixed tothe unitary body. The liner may comprise a fabric sock such as a nylonliner or the like.

While illustrative embodiments have been illustrated and described, itwill be appreciated that various changes can be made therein withoutdeparting from the spirit and scope of the invention.

1. A sports boot comprising: a unitary body comprising a sole portionand an upper portion extending upwardly from the sole portion, the upperportion including a toe portion configured to enclose a portion of auser's foot, and a cuff portion configured to wrap about a user's ankle,the upper portion defining an elongate opening extending from the toeportion; a semi-rigid elongate support attached to the cuff portion ofthe unitary body; an external upper assembly attached to the unitarybody and covering only a portion of the unitary body; and a closuremeans extending across the elongate opening.
 2. The sports boot of claim1, wherein the unitary body comprises injection-molded ethylene vinylacetate.
 3. The sports boot of claim 1, wherein the external upperassembly comprises a side panel, a forefoot panel and an instep panelthat are preassembled prior to attachment to the unitary body.
 4. Thesports boot of claim 1, wherein the cuff portion includes an innersurface defining a recess that is shaped to receive the elongate supportsuch that the elongate support is flush with the inner surface of thecuff portion.
 5. The sports boot of claim 1, further comprising a tongueattached to a forefoot end of the elongate opening and extendingupwardly along the elongate opening.
 6. The sports boot of claim 1,further comprising a gusset attached to an interior surface of theunitary body and extends across the elongate opening.
 7. The sports bootof claim 1, further comprising an inner liner sock that covers aninterior surface of the unitary body.
 8. The sports boot of claim 1,further comprising a reinforcing panel engaging a surface of the unitarybody adjacent the elongate opening.
 9. The sports boot of claim 8,wherein the reinforcing panel engages an exterior surface of the unitarybody.
 10. The sports boot of claim 8, wherein the closure meanscomprises a plurality of lace keepers attached to the reinforcing paneland a lace that slidably engages the lace keepers.
 11. The sports bootof claim 8, wherein the unitary body is formed with a recess on theouter surface that is sized and configured to receive the reinforcingpanel.
 12. The sports boot of claim 1, further comprising a semi-rigidtoe cap support that is attached to the toe portion of the unitary body.13. The sports boot of claim 1, wherein the cuff portion of the unitarybody comprises a plurality of thickened sections.
 14. The sports boot ofclaim 13, wherein the thickened sections further comprise transversechannels for increasing the flexibility in a desired flexure direction.15. The sports boot of claim 1, wherein the semi-rigid elongate supportcomprises a webbing that is rigid in the tensile direction.
 16. A methodof constructing a sports boot comprising: injection molding a unitarybody comprising a sole portion and an upper portion extending upwardlyfrom the sole portion, the upper portion including a toe portionconfigured to enclose a portion of a user's foot, and an upwardlyextending back portion positioned to extend along a rear portion of auser's leg, the upper portion defining an elongate opening extendingfrom the toe portion to an upper end of the unitary body; attaching asemi-rigid support to the back portion of the unitary body; securelyaffixing a plurality of reinforcing panels to an outer surface of theunitary body; forming an external upper assembly; fixedly attaching theexternal upper assembly to the unitary body by attaching the externalupper assembly to the plurality of reinforcing panels.
 17. The method ofclaim 16, further comprising the step of attaching a webbing to theunitary body using at least some of the plurality of reinforcing panels.18. The method of claim 16, wherein the unitary body comprises aninjection-molded ethylene vinyl acetate.
 19. The method of claim 16,wherein the external upper assembly comprises a composite constructionhaving side panels that overlie a portion of the unitary body, forefootpanels that attach to the unitary body, and an instep panel that extendsover the toe portion of the unitary body.
 20. The method of claim 16,wherein the unitary body comprises relatively thick portions that arenot covered by the external upper assembly.